Advances in Manufacturing最新文献

{"title":"A mechanism-data hybrid-driven modeling method for predicting machine tool-cutting energy consumption","authors":"Yue Meng,&nbsp;Sheng-Ming Dong,&nbsp;Xin-Sheng Sun,&nbsp;Shi-Liang Wei,&nbsp;Xian-Li Liu","doi":"10.1007/s40436-024-00526-9","DOIUrl":"10.1007/s40436-024-00526-9","url":null,"abstract":"<div><p>High-quality development in the manufacturing industry is often accompanied by high energy consumption. The accurate prediction of the energy consumption of computer numerical control (CNC) machine tools, which plays a vital role in manufacturing, is of great importance in energy conservation. However, the existing research ignores the impact of multi-factor energy losses on the performance of machine tool energy consumption prediction models. The existing models must be selected and verified several times to determine the appropriate hyperparameters. Therefore, in this study, a machine tool energy consumption prediction method based on a mechanism and data-driven model that considers multi-factor energy losses and hyperparameter dynamic self-optimization is proposed to improve the accuracy and reduce the difficulty of hyperparameter tuning. The proposed multi-factor energy-loss prediction model is based on the theoretical prediction model of machine-tool cutting energy consumption. After creating the model, a hyperparameter search space embedding a tree-structured Parzen estimator (TPE) was designed based on Hyperopt to dynamically self-optimize the hyperparameters in the deep neural network (DNN) model. Finally, two sets of experiments were designed for verification and comparison with the theoretical and data models. The results showed that the energy consumption prediction performances of the proposed hybrid model in the two sets of experiments were 99% and 97%.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 1","pages":"167 - 195"},"PeriodicalIF":4.2,"publicationDate":"2024-12-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143109218","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Heterogeneous ablation behavior of SiCf/SiC composite by nanosecond pulse laser","authors":"Jia-Heng Zeng,&nbsp;Quan-Li Zhang,&nbsp;Yu-Can Fu,&nbsp;Jiu-Hua Xu","doi":"10.1007/s40436-024-00532-x","DOIUrl":"10.1007/s40436-024-00532-x","url":null,"abstract":"<div><p>Silicon carbide fiber-reinforced silicon carbide composites are preferred materials for hot-end structural parts of aero-engines. However, their anisotropy, heterogeneity, and ultra-high hardness make them difficult to machine. In this paper, 2.5-dimensional braided SiC_f/SiC composites were processed using a nanosecond pulsed laser. The temperature field distribution at the laser ablated spot is analyzed through finite element modeling (FEM), and the ablation behavior of the two main components, SiC fiber and SiC matrix, is explored. A plasma plume forms when the pulse energy is sufficiently high, which increases with growing energy. The varied ablation behavior of the components is investigated, including the removal rate, ablative morphology, and phase transition. The ablation thresholds of SiC matrix and SiC fiber are found to be 2.538 J/cm² and 3.262 J/cm², respectively.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 1","pages":"196 - 210"},"PeriodicalIF":4.2,"publicationDate":"2024-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143108878","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Electrochemical grinding of honeycomb seals using sodium dodecylbenzene sulfonate as an eco-friendly inhibitor: machining principle and performance evaluation","authors":"Jin-Hao Wang,&nbsp;Lu Wang,&nbsp;Han-Song Li,&nbsp;Ning-Song Qu","doi":"10.1007/s40436-024-00531-y","DOIUrl":"10.1007/s40436-024-00531-y","url":null,"abstract":"<div><p>To enhance the performance of aero-engines, honeycomb seals are commonly used between the stator and rotor to reduce leakage and improve mechanical efficiency. Because of the thin-walled and densely distributed honeycomb holes, machining defects are prone to occur during manufacturing. Electrochemical grinding (ECG) can minimize machining deformation because it is a hybrid process involving electrochemical dissolution and mechanical grinding. However, electrolysis will generate excessive corrosion on the honeycomb surface, which affects the sealing capability and operational performance. In this study, an ECG method using an electrolyte of 10% (mass fraction) NaCl is proposed to machine the inner cylindrical surface of the honeycomb seal, and an eco-friendly inhibitor, sodium dodecylbenzene sulfonate (SDBS), is introduced to the electrolyte to inhibit corrosion of the honeycomb structure. A theoretical relationship between the voltage and feed rate during ECG is proposed, and the excessive corrosion of the honeycomb single-foiled segment is used as a measurement of the impact of electrolysis. The corrosion inhibition efficiency of SDBS on the honeycomb material in 10% (mass fraction) NaCl solution is evaluated through electrochemical tests, and the suitable feed rate and optimal concentration of SDBS are determined through ECG experiments. Additionally, the corrosion inhibition effect of SDBS is validated through four groups of comparative experiments. The results indicate that the inhibition efficiency of SDBS increases with increasing concentration, reaching the maximum of 73.44%. The optimal SDBS mass fraction is determined to be 0.06%. The comparative experiments show that excessive corrosion is reduced by more than 40%. This establishes ECG as an effective and environmentally friendly processing method for honeycomb seals by incorporating SDBS into a 10% (mass fraction) NaCl solution.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 1","pages":"229 - 244"},"PeriodicalIF":4.2,"publicationDate":"2024-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143108731","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Surface quality evaluation of cold plasma and NMQL multi-field coupling eco-friendly micro-milling 7075-T6 aluminum alloy","authors":"Zhen-Jing Duan,&nbsp;Shuai-Shuai Wang,&nbsp;Shu-Yan Shi,&nbsp;Ji-Yu Liu,&nbsp;Yu-Heng Li,&nbsp;Zi-Heng Wang,&nbsp;Chang-He Li,&nbsp;Yu-Yang Zhou,&nbsp;Jin-Long Song,&nbsp;Xin Liu","doi":"10.1007/s40436-024-00530-z","DOIUrl":"10.1007/s40436-024-00530-z","url":null,"abstract":"<div><p>Micromilling has been extensively employed in different fields such as aerospace, energy, automobiles, and healthcare because of its efficiency, flexibility, and versatility in materials and structures. Recently, nanofluid minimum quantity lubrication (NMQL) has been proposed as a green and economical cooling and lubrication method to assist the micromilling process; however, its effect is limited because high-speed rotating tools disturb the surrounding air and impede the entrance of the nanofluid. Cold plasma can effectively enhance the wettability of lubricating droplets on the workpiece surface and promote the plastic fracture of materials. Therefore, the multifield coupling of cold plasma and NMQL may provide new insights to overcome this bottleneck. In this study, experiments on cold plasma + NMQL multifield coupling-assisted micromilling of a 7075-T6 aluminum alloy were conducted to analyze the three-dimensional (3D) surface roughness (<i>S</i>_a), surface micromorphology, burrs of the workpiece, and milling force at different micromilling depths. The results indicated that, under cold plasma + NMQL, the workpiece surface micromorphology was smooth with fewer burrs. In comparison with dry, N₂, cold plasma, and NMQL, the <i>S</i>_a values at different cutting depths (5, 10, 15, 20 and 30 μm) were relatively smaller under cold plasma + NMQL with 0.035, 0.036, 0.041, 0.043 and 0.046 μm, which were respectively reduced by 38.9%, 45.7%, 45.9%, 47% and 48.9% when compared to the dry. The effect of cold plasma + NMQL multifield coupling-assisted micromilling on enhancing the workpiece surface quality was analyzed using mechanical analysis of tensile experiments, surface wettability, and X-ray photoelectron spectroscopy (XPS).</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 1","pages":"69 - 87"},"PeriodicalIF":4.2,"publicationDate":"2024-11-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143108461","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Mechanism and machinability in novel electroplastic-assisted grinding ductile iron","authors":"Jia-Hao Liu,&nbsp;Dong-Zhou Jia,&nbsp;Chang-He Li,&nbsp;Yan-Bin Zhang,&nbsp;Ying Fu,&nbsp;Zhen-Lin Lv,&nbsp;Shuo Feng","doi":"10.1007/s40436-024-00533-w","DOIUrl":"10.1007/s40436-024-00533-w","url":null,"abstract":"<div><p>Owing to the hard brittle phase organization in their matrixes, brittle materials are prone to the formation of pits and cracks on machined surfaces under extreme grinding conditions, which severely affect the overall performance and service behavior of machined parts. Based on the electroplastic effect of pulsed currents during material deformation, this study investigates electroplastic-assisted grinding with different electrical parameters (current, frequency, and duty cycle). The results demonstrate that compared to conventional grinding, the pulsed current can significantly decrease the surface roughness (<i>S</i>_a) of the workpiece and reduce surface pits and crack defects. The higher the pulsed current, the more pronounced the improvement in the surface quality of the workpiece. Compared to traditional grinding, when the pulsed current is 1 000 A, <i>S</i>_a decreases by 46.4%, and surface pit and crack defects are eliminated. Under the same pulse-current amplitude and frequency conditions, the surface quality continues to improve as the duty cycle increases. When the duty cycle is 75%, <i>S</i>_a reaches a minimum of 0.749 μm. However, the surface quality is insensitive to the pulsed-current frequency. By investigating the influence of pulsed electrical parameters on the surface quality of brittle material under grinding conditions, this study provides a theoretical basis and technical support for improving the machining quality of hard, brittle materials.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 1","pages":"245 - 263"},"PeriodicalIF":4.2,"publicationDate":"2024-11-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143108620","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effects of tool coating and tool wear on the surface and chip morphology in side milling of Ti2AlNb intermetallic alloys","authors":"Xin Wang,&nbsp;Qing-Liao He,&nbsp;Biao Zhao,&nbsp;Wen-Feng Ding,&nbsp;Qi Liu,&nbsp;Dong-Dong Xu","doi":"10.1007/s40436-024-00527-8","DOIUrl":"10.1007/s40436-024-00527-8","url":null,"abstract":"<div><p>Ti₂AlNb intermetallic alloys, which belong to the titanium aluminum (TiAl) family, are currently being extensively researched and promoted in the aerospace industry because of their exceptional properties, including low density, high-temperature strength, and excellent oxidation resistance. However, the excellent fracture toughness of the material leads to the formation of surface defects during machining, thereby affecting the quality of the machined surface. In this study, Ti₂AlNb intermetallic alloys were subjected to side-milling trials to investigate the influence of tool coating and tool wear on both the machined surface quality and chip morphology. Specifically, the tool life, machined surface roughness, surface morphology, surface defects, and chip morphology were investigated in detail. The results indicated that the tool coating provided a protective effect, resulting in a threefold increase in the service life of the coated end mill compared to that of the uncoated one. A coated end mill yields a superior machined surface topography, as evidenced by reduced roughness and a more consistent morphology. Tool wear has a significant effect on the morphology of machined surfaces. The occurrence of material debris and feed marks became increasingly severe as the tool wore off. The chip morphology was not significantly affected by the tool coating. However, tool wear results in severe tearing along the chip edge, obvious plastic flow on the non-free surface, and a distinct lamellar structure on the free surface.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 1","pages":"155 - 166"},"PeriodicalIF":4.2,"publicationDate":"2024-11-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143108540","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"High-speed grinding: from mechanism to machine tool","authors":"Yu-Long Wang,&nbsp;Yan-Bin Zhang,&nbsp;Xin Cui,&nbsp;Xiao-Liang Liang,&nbsp;Run-Ze Li,&nbsp;Ruo-Xin Wang,&nbsp;Shubham Sharma,&nbsp;Ming-Zheng Liu,&nbsp;Teng Gao,&nbsp;Zong-Ming Zhou,&nbsp;Xiao-Ming Wang,&nbsp;Yusuf Suleiman Dambatta,&nbsp;Chang-He Li","doi":"10.1007/s40436-024-00508-x","DOIUrl":"10.1007/s40436-024-00508-x","url":null,"abstract":"<div><p>High-speed grinding (HSG) is an advanced technology for precision machining of difficult-to-cut materials in aerospace and other fields, which could solve surface burns, defects and improve surface integrity by increasing the linear speed of the grinding wheel. The advantages of HSG have been preliminarily confirmed and the equipment has been built for experimental research, which can achieve a high grinding speed of more than 300 m/s. However, it is not yet widely used in manufacturing due to the insufficient understanding on material removal mechanism and characteristics of HSG machine tool. To fill this gap, this paper provides a comprehensive overview of HSG technologies. A new direction for adding auxiliary process in HSG is proposed. Firstly, the combined influence law of strain hardening, strain rate intensification, and thermal softening effects on material removal mechanism was revealed, and models of material removal strain rate, grinding force and grinding temperature were summarized. Secondly, the constitutive models under high strain rate boundaries were summarized by considering various properties of material and grinding parameters. Thirdly, the change law of material removal mechanism of HSG was revealed when the thermodynamic boundary conditions changed, by introducing lubrication conditions such as minimum quantity lubrication (MQL), nano-lubricant minimum quantity lubrication (NMQL) and cryogenic air (CA). Finally, the mechanical and dynamic characteristics of the key components of HSG machine tool were summarized, including main body, grinding wheel, spindle and dynamic balance system. Based on the content summarized in this paper, the prospect of HSG is put forward. This study establishes a solid foundation for future developments in the field and points to promising directions for further exploration.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 1","pages":"105 - 154"},"PeriodicalIF":4.2,"publicationDate":"2024-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40436-024-00508-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143108711","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Grinding defect characteristics and removal mechanism of unidirectional Cf/SiC composites","authors":"Chong-Jun Wu,&nbsp;Fei Liu,&nbsp;Jia-Zhou Wen,&nbsp;Pei-Yun Xia,&nbsp;Steven Y. Liang","doi":"10.1007/s40436-024-00521-0","DOIUrl":"10.1007/s40436-024-00521-0","url":null,"abstract":"<div><p>Owing to their brittleness and heterogeneity, achieving carbon fiber-reinforced silicon carbide ceramic (C_f/SiC) composites with ideal dimensional and shape accuracy is difficult. In this study, unidirectional C_f materials were subjected to orthogonal grinding experiments using different fiber orientations. Through a combined analysis of the surface morphology and grinding force after processing, the mechanism underlying the effect of the fiber orientation on the surface morphology of the material was explained. The surface roughness of the material was less affected by the process parameters and fluctuated around the fiber radius scale; the average surface roughness (<i>R</i>_a) in the direction of scratching parallel (SA) and perpendicular (SB) to the fiber direction was 4.21‒5.00 μm and 4.42‒5.26 μm, respectively; the material was mainly removed via the brittle removal mechanism; and the main defects of the fiber in the SA direction were tensile fracture and extrusion fracture; the main defects of the fiber in the SB direction were bending fracture, shear fracture, and fiber debonding. The grinding parameters influenced the grinding force in the order: depth of cut &gt; feed rate &gt; wheel speed. The grinding force increased with an increase in the feed rate or depth of cut and decreased with an increase in the wheel speed. Moreover, increasing the depth of cut was more effective in decreasing the grinding force and improving the material removal efficiency than adjusting the rotational speed of the workpiece and the rotational speed of the grinding wheel. The specific grinding energy decreased with an increase in the feed rate or depth of cut, and increased with an increase in the grinding wheel speed.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"13 1","pages":"211 - 228"},"PeriodicalIF":4.2,"publicationDate":"2024-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142248759","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The effect of the slope angle and the magnetic field on the surface quality of nickel-based superalloys in blasting erosion arc machining","authors":"Lin Gu, Ke-Lin Li, Xiao-Ka Wang, Guo-Jian He","doi":"10.1007/s40436-024-00523-y","DOIUrl":"https://doi.org/10.1007/s40436-024-00523-y","url":null,"abstract":"<p>Electrical arc machining (EAM) is an efficient process for machining difficult-to-cut materials. However, limited research has been conducted on sloped surface machining within this context, constraining the further application for complex components. This study conducts bevel machining experiments, pointing out that the surface quality becomes unsatisfactory with the increasing bevel angle. The discharge condition is counted and analyzed, while the flow field and the removed particle movement of the discharge gap are simulated, demonstrating the primary factor contributing to the degradation of surface quality, namely the loss of flushing. This weakens both the plasma control effect and debris evacuation, leading to the poor discharge condition. To address this issue, the magnetic field is implemented in blasting erosion arc machining (BEAM). The application of a magnetic field effectively regulates the arc plasma, enhances debris expulsion, and significantly improves the discharge conditions, resulting in a smoother and more uniform sloped surface with a reduced recast layer thickness. This approach provides the possibility of applying BEAM to complex parts made of difficult-to-cut materials in aerospace and military industries.</p>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"4 1","pages":""},"PeriodicalIF":5.2,"publicationDate":"2024-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204434","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Study on the mechanism of burr formation in ultrasonic vibration-assisted honing 9Cr18MoV valve sleeve","authors":"Peng Wang, Chang-Yong Yang, Ying-Ying Yuan, Yu-Can Fu, Wen-Feng Ding, Jiu-Hua Xu, Yong Chen","doi":"10.1007/s40436-024-00516-x","DOIUrl":"https://doi.org/10.1007/s40436-024-00516-x","url":null,"abstract":"<p>The precision, lifespan, and stability of the electro-hydraulic servo valve sleeve are significantly impacted by the edge burrs that are easily created when honing the valve sleeve. The existing deburring process mainly rely on manual operation with high cost and low efficiency. This paper focuses on reducing the burr size during the machining process. In this paper, a single-scratch test with a finite element simulation model is conducted to study the mechanism of burr generation. The tests were carried out under ultrasonic vibration and non-ultrasonic vibration conditions to explore the effect of ultrasonic vibration on burrs. Besides, a honing experiment is conducted to verify the conclusions. The results at various cutting parameters are analyzed, and the mechanism of burr generation is revealed. The stiffness lacking of the workpiece edge material is the main reason for the burr generation. The cutting depth shows a significant effect on burr size while the cutting speed does not. The inhibition mechanism of ultrasonic vibration on burrs is also revealed. The separation of the burr stress field under ultrasonic vibration and the higher bending hinge point is the reason for burr fracturing. The re-cutting effect of ultrasonic vibration reduces the burr growth rate. The results of the honing experiment verified these conclusions and obtained a combination of honing parameters to minimize the burr growth rate.</p>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"4 1","pages":""},"PeriodicalIF":5.2,"publicationDate":"2024-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142226122","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}